1st Edition

Roll Forming Handbook

Edited By George T. Halmos Copyright 2006
    582 Pages 723 B/W Illustrations
    by CRC Press

    Roll forming is one of the most widely used processes in the world for forming metals. Most of the existing knowledge resides in various journal articles or in the minds of those who have learned from experience. Providing a vehicle to systematically collect and share this important knowledge, the Roll Forming Handbook presents the first comprehensive, dedicated treatment to all facets of roll forming, supplying references to more in-depth information to fill in the gaps.

    This book spans from conception of the roll forming operation, purchasing and specifying equipment, and roll design to maintenance, troubleshooting, safety, and operator training. Detailed discussions reveal how material, equipment, tooling, and operator factors affect overall efficiency and product quality. Expert contributors share insights based on many years of hard-won experience, including effects of secondary operations such as punching, embossing, curving and cutting in the line; designing products for efficient roll forming; mechanical properties of metals, lubrication and the influence of coatings on roll design and forming; and mathematical simulations of various deformations that occur during processing to determine their causes and find a solution.

    Outlining a practical approach to select, set up, and operate roll forming lines, the Roll Forming Handbook combines scientific background and practical know-how that enables you to set up cost-effective and high-quality roll forming lines with confidence.

    INTRODUCTION TO ROLL FORMING; George T. Halmos
    Introduction to Roll Forming
    ROLL FORMING MILL; George T. Halmos
    General
    Mill Types
    Mill Components
    References
    PRESSES AND DIE ACCELERATORS; George T. Halmos
    General
    Mechanical Presses
    Pneumatic Presses
    Hydraulic Presses
    Information and Dimensions for Press/Die Purchasing and Installation
    Rotary and Other Cutting, Punching Equipment
    Flying Die Accelerators
    SECONDARY OPERATIONS IN THE ROLL FORMING LINE; George T. Halmos
    Secondary Operations
    Straightening
    Tight or Loose Line: Cutting Before, In-Between, or After Roll Forming
    Location of the Secondary Operations
    Stationary and Flying Dies
    Punching, Perforating, Notching, and Mitering
    Piercing and Partial Punching
    Flanging, Louvering, and Lancing
    Embossing and Drawing
    Bending
    Curving (Sweeping)
    Marking
    Swedging (Off Setting)
    Rotary Dies
    Mechanical Joining of Different Strips or Parts
    Adhesive Bonding
    Soldering and Brazing
    Resistance Welding
    Painting
    Foaming
    Packaging
    References
    ROLL DESIGN; George T. Halmos
    Roll Design Process
    Cross-Section
    Product Orientation and Other Operations in the Line
    Materials
    Roll Forming Mill
    Other Tool Design Considerations
    Spacers and Shims
    Calculating Strip Width
    Bend Lines
    Number of Passes
    Flower Diagram
    Roll Design
    Calculating Roll Dimensions Manually
    Computer-Aided Roll Design
    Examples
    Roll Marking System
    Roll Orientation
    Setup Charts
    References
    MATERIALS; George T. Halmos
    Design Considerations
    Mechanical Properties
    Crystalline Structure of Metals
    Forming Metals
    Increasing the Strength of Metals by Cold Working
    Hot Rolling
    H.R. and H.R.P.O. Steels
    Cold Rolled Steel
    Carbon Steel
    Alloyed Steel
    Stainless Steel
    Metallic Coatings
    Nonmetallic Coating and Laminating
    Joining Different Materials in the Roll Forming Process
    Aluminum
    Other Metals and Materials
    Influence of Primary Metal Processes on Roll Forming
    Guideline to Steel Prices
    References
    LUBRICATION; Joseph Ivaska
    Tribology of Lubrication
    Selection of Lubricants
    Surface Properties of Formed Material
    Lubricants for the Secondary Operations
    Application Techniques
    Preparation and Maintenance of Lubricants
    Operating Problems during Production
    COIL PROCESSING, MATERIAL HANDLING, AND PLANT LAYOUT; George T. Halmos and Joseph Horvath
    Flow of Material
    Coil Handling and Storage
    Sheet Handling and Storage
    In-Line Coil Handling
    Coil End Welding
    Strip (Coil) Accumulators
    Flattening and Leveling
    In-Line Sheet Handling
    Finished Product Handling
    Finished Product Storage
    Material Handling Equipment
    Material Handling Accessories
    Crane Controls
    Plant Layout
    References
    DESIGNING PRODUCTS FOR ROLL FORMING; George T. Halmos
    Developing Light Gage Products
    Design Considerations
    Secondary Operations
    Profiles Manufactured in Different Sizes
    Design of Specific Products
    Dimensioning and Tolerancing
    References
    EQUIPMENT INSTALLATION, ROLL SETUP, MAINTENANCE, AND TROUBLESHOOTING; George T. Halmos
    Installation of Roll Forming Lines
    Roll Installation and Setup
    Maintenance and Spare Parts
    Troubleshooting and Trouble Prevention
    BEHAVIOR OF METAL STRIP DURING ROLL FORMING; Manabu Kiuchi
    Various Types of Deformations
    Causes of Redundant Deformations
    Effects of Redundant Deformations on Product Defects
    Mathematical Simulation of the Deformation of a Metal Strip
    Computerized Design System for Roll Profiles
    CAE for Roll Forming
    ACQUIRING ROLL FORMING LINES, EDUCATION, AND TRAINING; George T. Halmos
    Why Roll Form Products?
    Different Paths to Start Roll Forming
    Evaluating the Product
    Selecting Line Components
    Procuring Roll Forming Tooling
    Equipment and Tool Specifications
    Acceptance Test
    Education and Training
    Motivation
    References
    SAFETY; Ashok Shah
    Safety
    Common Safety-Related Definitions
    Safety Design Procedure
    Determining Limits of the Machinery or System
    Determining Hazards/Risk Estimation
    Risk Reduction by Design
    Safeguarding
    Selection of Guards and Protective Devices
    Required Characteristics of Guards and Protection Devices
    Signals and Warning Devices
    Personal Protective Equipment
    Training
    Summary
    References
    INCREASING EFFICIENCY OF ROLL FORMING LINES AND CASE STUDIES; George T. Halmos
    Output, Productivity, and Efficiency
    Line Utilization
    Improving Productivity
    Case Studies
    Preliminary Tool and Equipment Cost Analysis
    Preliminary Cost Analysis
    UNUSUAL, NEW, AND FUTURE ROLL FORMING TECHNOLOGIES; George T. Halmos
    The Last 100 Years
    The Future of Roll Forming
    Pull-Through Mills: Nondriven Rolls
    Tension Roll Forming
    Combining Roll Forming and Cold Drawing
    Developing New Roll Forming Methods
    Roll Forming Tools
    Reducing the Thickness of the Starting Material
    Forming at Elevated Temperature
    Hot Roll Forming Variable Cross-Sections
    Hot Thickness Reduction along the Length of the Strip
    Welding Hot Roll Formed Sections
    Other "Hot" Processes
    In-Line Soldering, Brazing, and Heat Treating
    Equipment and Tooling Requirements for Hot Roll Forming
    Press Tooling for Conventional Roll Forming Lines
    Computer-Controlled Roll Forming Lines
    References
    APPENDICES
    REFERENCES
    INDEX

    Biography

    George T. Halmos